System and method for monitoring stress of high-temperature thick-wall part of power station boiler

Abstract

The invention relates to the technical field of power generation, in particular to a power station boiler high-temperature thick-wall component stress monitoring system and method.The system comprises at least one high-temperature strain gauge, at least one high-temperature sensor, at least one high-temperature sensor, at least one high-temperature sensor and at least one high-temperature sensor, the at least one high-temperature strain gauge deforms under the condition that the temperature of the wall surface is greater than a preset temperature; the at least one temperature sensor is used for collecting the actual temperature of the high-temperature thick-wall part of the power station boiler; the at least one strain collector is used for generating a strain value of the at least one high-temperature strain gauge; and the monitoring assembly is used for inquiring the material elasticity modulus of the power station boiler high-temperature thick-wall component by taking the actual temperature as an index, and calculating the stress value of the power station boiler high-temperature thick-wall component by combining the strain value. According to the invention, the high-temperature stress-strain testing technology can be applied to the stress online monitoring of the high-temperature thick-wall part of the thermal power plant boiler, and the safety risk caused by creep-fatigue damage during the operation of the high-temperature thick-wall pipeline can be effectively predicted.

Description

Technical Field

[0001] The present application relates to the field of power generation technology, and in particular to a stress monitoring system and method for high-temperature thick-walled components of power station boilers. Background Art

[0002] In the context of building new power systems, thermal power plants often utilize wide-load, fast, and flexible peak-shaving technologies. Frequent load fluctuations negatively impact the safety and service life of high-temperature, thick-walled components in thermal power plant boilers. Research has shown that damage to metal components in power plants is closely related to prolonged high-temperature operation and the stress state of the components. Therefore, online stress and strain monitoring of high-temperature, thick-walled components in ultra-supercritical power plant boilers, enabling the acquisition of dynamic, real-time, and online stress and strain data, is widely needed and has significant application value.

[0003] Prior art monitoring of the stress state of thick-walled components in power plant boilers primarily relies on inspections of pipe supports and hangers during regular inspections of thermal power units, as well as analysis of the stress state of metal components. This is a post-inspection approach. Real-time stress monitoring technology is primarily used for pipe supports and hangers, which are relatively low-temperature applications.

[0004] However, in the relevant technology, traditional stress monitoring equipment and stress state monitoring methods are not suitable for the thick-walled components of boilers of high-parameter thermal power units that can even reach temperatures above 600°C during operation. They cannot work in harsh high-temperature environments. Moreover, the thick-walled components of boilers are widely distributed, and the distance between high-temperature headers is relatively far, making real-time monitoring difficult, which urgently needs to be solved. Summary of the Invention

[0005] The present application provides a stress monitoring system and method for high-temperature thick-walled components of power station boilers to address the problems in related technologies, such as the fact that traditional stress monitoring equipment and stress state monitoring methods are not suitable for thick-walled boiler components of high-parameter thermal power units that can even reach temperatures above 600°C during operation, are unable to operate in harsh high-temperature environments, and are also difficult to monitor in real time because thick-walled boiler components are widely distributed and the distances between high-temperature headers are relatively far.

[0006] A first aspect of the present application provides a stress monitoring system for high-temperature, thick-walled components of a power station boiler, comprising: at least one high-temperature strain gauge, wherein the at least one high-temperature strain gauge is arranged on the wall surface of the high-temperature, thick-walled component of the power station boiler, and the at least one high-temperature strain gauge deforms when the temperature of the wall surface is greater than a preset temperature; at least one temperature sensor for collecting the actual temperature of the high-temperature, thick wall of the power station boiler; at least one strain collector for generating the strain value of the at least one high-temperature strain gauge; and a monitoring component for querying the material elastic modulus of the high-temperature, thick-walled component of the power station boiler using the actual temperature as an index, and calculating the stress value of the high-temperature, thick-walled component of the power station boiler based on the material elastic modulus and the strain value.

[0007] Optionally, in one embodiment of the present application, the at least one temperature sensor includes: a temperature measuring thermocouple, used to generate a voltage signal of the high-temperature thick-walled components of the power station boiler; and at least one temperature collector, used to generate the actual temperature of the high-temperature thick-walled components of the power station boiler based on the voltage signal.

[0008] Optionally, in one embodiment of the present application, the monitoring component includes: a controller for collecting the actual temperature and the strain value; a server for receiving the actual temperature and the strain value sent by the controller, querying the material elastic modulus, and calculating the stress value of the high-temperature thick-walled component of the power station boiler based on the material elastic modulus and the strain value.

[0009] Optionally, in one embodiment of the present application, it further includes: an installation component for determining at least one stress change monitoring position of at least one thick-walled component of a power plant boiler based on a stress distribution cloud map of the at least one thick-walled component of the power plant boiler, so as to correspondingly set the at least one high-temperature strain gauge.

[0010] Optionally, in one embodiment of the present application, it also includes: a generation component for performing finite element stress numerical simulation of the thick-walled components of the power station boiler and the pipelines within the target range around them based on the structural information of the thick-walled components of the power station boiler and the temperature parameters and pressure parameters of the thick-walled components during operation of the power station boiler, so as to generate the stress distribution cloud map.

[0011] A second aspect of the present application provides a method for monitoring the stress of high-temperature thick-walled components of a power station boiler, using the above-mentioned stress monitoring system for high-temperature thick-walled components of a power station boiler, wherein the method includes the following steps: collecting the actual temperature of the high-temperature thick wall of the power station boiler; generating the strain value of the at least one high-temperature strain gauge based on the deformation of the at least one high-temperature strain gauge; using the actual temperature as an index, querying the material elastic modulus of the high-temperature thick wall of the power station boiler, and calculating the stress value of the high-temperature thick wall of the power station boiler based on the material elastic modulus and the strain value.

[0012] A third aspect of the present application provides an electronic device, comprising: a memory, a processor, and a computer program stored on the memory and executable on the processor, wherein the processor executes the program to implement the stress monitoring method for high-temperature thick-walled components of a power plant boiler as described in the above embodiment.

[0013] A fourth aspect of the present application provides a computer-readable storage medium, which stores a computer program. When the program is executed by a processor, it implements the above-mentioned method for monitoring stress of high-temperature thick-walled components of power station boilers.

[0014] A fifth aspect of the present application provides a computer program product, including a computer program. When the computer program is executed, it is used to implement the above-mentioned method for monitoring stress of high-temperature thick-walled components of power station boilers.

[0015] In embodiments of the present application, high-temperature strain gauges and temperature-measuring thermocouples can be used to measure the strain and actual temperature of high-temperature, thick-walled components of power station boilers, and the stress of these components can be calculated based on the material elastic modulus corresponding to the strain and actual temperature. This utilizes high-temperature strain gauges as a transmission medium, with strain and temperature collectors collecting data, which is then aggregated by a controller and ultimately transmitted to a server. This allows for real-time online stress monitoring, even in environments exceeding 600°C, through signal transmission and conversion. Furthermore, to address the diverse and dispersed nature of thick-walled components in power station boilers, the present application employs a modular design. Each collector is a module, allowing for simultaneous stress and temperature monitoring of multiple locations within the boiler's thick-walled components. In the event of a module failure, only the collector needs to be replaced, resulting in a simple structure and easy maintenance. Furthermore, to address the long distance between power station boilers and the power station's centralized control room, the controller in the present application supports simultaneous expansion of multiple controllers, supporting both series and star connections, adapting to various online monitoring scenarios. This solves the problem in related technologies that traditional stress monitoring equipment and stress state monitoring methods are not suitable for thick-walled boiler components of high-parameter thermal power units that can even reach temperatures above 600°C during operation. They cannot work in harsh high-temperature environments. Moreover, the thick-walled boiler components are widely distributed, and the distance between high-temperature headers is far. The installation cost is high and the signal is easily interfered with. The applicable scenarios are limited, the subsequent system maintenance is inconvenient, and real-time monitoring is also difficult.

[0016] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become apparent from the description below, or will be learned through practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the following description of the embodiments in conjunction with the accompanying drawings, in which:

[0018] Figure 1 This is a schematic structural diagram of a stress monitoring system for high-temperature thick-walled components of a power station boiler provided according to an embodiment of the present application;

[0019] Figure 2 This is a schematic diagram of the welding installation of a high-temperature strain gauge according to one embodiment of the present application;

[0020] Figure 3 This is a schematic diagram of the installation of an armored temperature measuring thermocouple according to one embodiment of the present application;

[0021] Figure 4 This is a schematic diagram of the installation structure of a stress monitoring system for high-temperature thick-walled components of a power station boiler according to one embodiment of the present application;

[0022] Figure 5 This is a flow chart of a method for monitoring stress of high-temperature thick-walled components of a power station boiler according to one embodiment of the present application;

[0023] Figure 6 This is a flow chart of a method for monitoring stress of high-temperature thick-walled components of a power station boiler according to an embodiment of the present application;

[0024] Figure 7 A schematic diagram of the structure of an electronic device provided according to an embodiment of the present application.

[0025] Reference numerals:

[0026] 10-Stress monitoring system for high-temperature, thick-walled components of power plant boilers: at least one high-temperature strain gauge, at least one temperature sensor, at least one strain collector, and 400-monitoring component; 701-memory, 702-processor, and 703-communication interface; 1-boiler thick-wall component, 2-high-temperature strain gauge, 3-temperature measuring thermocouple, 4-transmission wire, 5-strain collector, 6-temperature collector, 7-controller, 8-network cable, 9-fiber optic transceiver, 10-optical fiber, 11-server. DETAILED DESCRIPTION

[0027] The following describes in detail embodiments of the present application, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present application, and should not be construed as limiting the present application.

[0028] The following describes a stress monitoring system and method for high-temperature thick-walled components of power station boilers according to an embodiment of the present application with reference to the accompanying drawings. In view of the fact that conventional stress monitoring equipment and stress state monitoring methods in the related technologies mentioned in the above background technology are not suitable for thick-walled components of boilers of high-parameter thermal power units, which can even reach temperatures above 600°C during operation, and cannot operate in harsh high-temperature environments, and that thick-walled components of boilers are widely distributed and the distances between high-temperature headers are relatively far, making real-time monitoring difficult, the present application provides a stress monitoring system for high-temperature thick-walled components of power station boilers. In this system, high-temperature strain gauges and temperature-measuring thermocouples can be used to measure the strain value and actual temperature of the high-temperature thick-walled components of the power station boilers, and the stress value of the high-temperature thick-walled components of the power station boilers can be calculated based on the material elastic modulus corresponding to the strain value and the actual temperature. As a result, high-temperature strain gauges are used as transmission media, and strain collectors and temperature collectors are used to collect data, which are then aggregated by the controller and finally transmitted to the server. Even in a high-temperature environment of over 600°C, the online monitoring value of stress can be obtained in real time through signal transmission and conversion. Furthermore, in view of the characteristics of the large variety and scattered locations of thick-walled components of power station boilers, this application adopts a modular design. Each collector is a module, and multiple modules can be set up to simultaneously monitor the stress and temperature of multiple locations of thick-walled components of the boiler. If a module fails, only the collector needs to be replaced, and the structure is simple and maintenance is convenient. In addition, considering the long distance between the power station boiler and the power station control room, the controller in this application can support the simultaneous expansion of multiple controllers, support series or star connection, and can adapt to various online monitoring sites. This solves the problem in related technologies that traditional stress monitoring equipment and stress state monitoring methods are not suitable for thick-walled boiler components of high-parameter thermal power units that can even reach temperatures above 600°C during operation. They cannot work in harsh high-temperature environments. Moreover, the thick-walled boiler components are widely distributed, and the distance between high-temperature headers is far. The installation cost is high and the signal is easily interfered with. The applicable scenarios are limited, the subsequent system maintenance is inconvenient, and real-time monitoring is also difficult.

[0029] Specifically, Figure 1 This is a structural schematic diagram of a stress monitoring system for high-temperature thick-walled components of a power station boiler provided in an embodiment of the present application.

[0030] like Figure 1 As shown, the power station boiler high-temperature thick-wall component stress monitoring system 10 includes:

[0031] At least one high temperature strain gauge (such as Figure 1 As shown, high-temperature strain gauges 101, 102, ..., 10N), at least one high-temperature strain gauge is disposed on the wall surface of a high-temperature thick-walled component of a power plant boiler, and at least one high-temperature strain gauge deforms when the temperature of the wall surface is greater than a preset temperature.

[0032] Professionals and technicians in this field will understand that with the development of high-parameter thermal power units such as 1000MW, the thick-walled components of their boilers can even reach temperatures exceeding 600°C during operation. In this case, traditional stress monitoring equipment is not suitable for measuring the stress of high-temperature, thick-walled components in power station boilers because traditional stress monitoring equipment cannot operate in harsh high-temperature environments (such as above 600°C). It should be noted that here and in the subsequent description, the thick-walled boiler components refer to the high-temperature, thick-walled components of power station boilers.

[0033] In some embodiments, the present application may place at least one high-temperature strain gauge on the surface of a thick-walled boiler component. Information related to the strain in the thick-walled boiler component can then be obtained based on the mechanical deformation of the at least one high-temperature strain gauge when the wall temperature exceeds a preset temperature. The preset temperature can be understood as a temperature at which the high-temperature strain gauge can deform, such as 600°C.

[0034] Here, the high-temperature strain gauge can be understood as a sensor element used to measure the surface strain of thick-walled boiler components in high-temperature environments. Its principle is based on the piezoresistive effect of metal or semiconductor materials, that is, the resistance value of the material will change with the strain generated by the force it is subjected to. In a high-temperature environment, when the thick-walled boiler components are deformed due to heat or force, the high-temperature strain gauge attached to the surface of the thick-walled boiler components will also produce corresponding mechanical deformation, resulting in a change in the resistance value of the high-temperature strain gauge. By measuring the change in resistance value, the strain borne by the surface of the object can be calculated. Among them, strain represents the degree of change in the shape or size of the thick-walled boiler components relative to the original state under the action of external force. It is a dimensionless quantity that can reflect the deformation inside the thick-walled boiler components.

[0035] Furthermore, considering the widespread distribution of thick-walled boiler components and the long distances between high-temperature headers, the present invention allows for different high-temperature strain gauges to be installed on the walls (surfaces) of different high-temperature thick-walled components within a power plant boiler. For example, high-temperature strain gauge 101 can be installed on the wall of the steam-water separator; high-temperature strain gauge 102 can be installed on the wall of the high-temperature header; and high-temperature strain gauges 103, 10N, and so on can be installed on various high-temperature pipes within the boiler.

[0036] In the embodiment of the present application, high-temperature strain gauges can be installed on high-temperature components of power plant boilers, steam turbines and other equipment. The high-temperature strain gauges can be used to monitor the strain of the components during operation, providing a basis for equipment safety assessment and fault diagnosis.

[0037] Optionally, in one embodiment of the present application, it also includes: an installation component for determining at least one stress change monitoring position of at least one thick-walled component of a power plant boiler based on a stress distribution cloud map of at least one thick-walled component of a power plant boiler, so as to correspondingly set at least one high-temperature strain gauge.

[0038] Based on the relevant descriptions of other embodiments, it can be understood that the present application can set different high-temperature strain gauges on the wall surfaces (surfaces) of different high-temperature thick-walled components of power station boilers.

[0039] In certain embodiments, when different high-temperature strain gauges are set on the wall surfaces of these different high-temperature thick-walled components of power station boilers, considering that different positions on the wall surfaces of different high-temperature thick-walled components of power station boilers have different stress changes, the present application can set up an installation component to use the stress distribution cloud map of at least one power station boiler thick-walled component to determine at least one stress change monitoring position of at least one power station boiler thick-walled component, so as to set at least one high-temperature strain gauge accordingly.

[0040] Among them, the stress distribution cloud map of the thick-walled components of the boiler is a visualization tool that intuitively displays the internal stress distribution of the thick-walled components of the boiler in a graphical manner. Through the stress distribution cloud map of the thick-walled components of the boiler, the embodiment of the present application can determine which parts of the thick-walled components of the boiler have stress concentration phenomena. For example, at the corners of thick-walled components, near welds, around openings, etc., due to sudden changes in geometric shapes or differences in material properties, stress concentration is often prone to occur. In the stress distribution cloud map, these areas will appear as darker colors or parts with a large color difference from the surrounding areas. Therefore, the embodiment of the present application can determine these locations with higher stress concentration and damage risks as locations for subsequent monitoring, that is, to install at least one high-temperature strain gauge at at least one of these stress change monitoring locations.

[0041] Furthermore, considering the presence of a metal oxide layer on the surface of the thick-walled parts of the boiler, the embodiment of the present application can also define the pretreatment of at least one stress change monitoring position during actual installation. For example, the present application can use an angle grinder to perform arc-shaped grinding on the surface within the range of 250*350mm of the part to be measured to remove the oxide layer and make the surface present a metallic luster. After grinding, use absorbent cotton dipped in anhydrous ethanol to clean it in the same direction to remove impurities on the surface of the part to be measured. After cleaning, wait until the surface is dry, align the high-temperature strain gauge with the surface of the thick-walled part to be measured, and the positions of the triangular positioning marks on both sides of the high-temperature strain gauge are the positions where the surface needs to be welded and fixed. Place a short piece of paper tape on the lower part of the high-temperature strain gauge assembly and stick it to the surface to be measured as a temporary fixed position.

[0042] Furthermore, the embodiments of the present application may further define a method for fixing a high-temperature strain gauge. Figure 2This is a schematic diagram of the welding installation of a high temperature strain gauge according to an embodiment of the present application. Figure 2 As shown, in the embodiment of the present application, a portable handheld spot welder can be used to spot weld and fix the high-temperature strain gauge. Start spot welding at the positions of the triangular positioning marks on both sides of the high-temperature strain gauge, and weld a point every 1.6mm around the high-temperature strain gauge until one circle of welding is completed. During the welding process, remove the paper tape used for temporary fixation in reverse parallel. Continue welding around the center of the high-temperature strain gauge at 0.8mm outside the first circle, and weld a point every 1.6mm to complete the second circle of welding. After the spot welding is completed, the signal transmission wire of the high-temperature strain gauge is led out of the insulation layer and protected with a high-temperature heat-melt shrink joint.

[0043] By adopting spot welding, the embodiment of the present application not only ensures the stability of the connection and contact between the high-temperature strain gauge and the surface of the monitored component, but also minimizes the destructiveness of welding to the stress and strain structure on the surface of the monitored structure, thereby improving the accuracy of real-time online stress monitoring.

[0044] It should be noted that the number of high-temperature strain gauges installed on any thick-walled component of a boiler can be determined by professionals in this field based on actual conditions. The embodiments of this application are only for illustrative purposes and are not specifically limited.

[0045] The embodiment of the present application can determine at least one stress change monitoring location based on the stress distribution cloud map of at least one thick-walled component of a power station boiler, and set at least one high-temperature strain gauge accordingly, so that at least one high-temperature strain gauge can be set at a location in the thick-walled component of the boiler where stress is concentrated and the risk of stress damage is higher, which helps to timely understand the strain conditions in high-risk areas of the thick-walled components of the boiler.

[0046] Optionally, in one embodiment of the present application, it also includes: a generation component for performing finite element stress numerical simulation of the thick-walled components of the power plant boiler and the pipelines within the target range around them based on the structural information of the thick-walled components of the power plant boiler and the temperature parameters and pressure parameters of the thick-walled components during operation of the power plant boiler to generate a stress distribution cloud map.

[0047] In the actual implementation process, before using the installation component to determine at least one stress change monitoring position based on the stress distribution cloud map of at least one thick-walled component of a power plant boiler to set at least one high-temperature strain gauge accordingly, the present application needs to first generate a stress distribution cloud map of at least one thick-walled component of a power plant boiler.

[0048] Specifically, the embodiments of the present application can perform finite element stress numerical simulation on the thick-walled components of power station boilers and the pipelines within a target range around them based on the structural information of the thick-walled components of power station boilers and the temperature and pressure parameters of the thick-walled components during operation. That is, after performing simulated stress calculations on the thick-walled components of the boilers under high-temperature conditions, the calculated stress data is presented in the form of a cloud map to obtain a cloud map of the overall stress distribution of the thick-walled components of the boilers. The target range here can be understood as the pipeline selection range set based on the location of the thick-walled components of the power station boilers when performing finite element stress numerical simulations, for example, the pipelines within a circular range with a radius of 1 meter with the thick-walled components of the power station boilers as the center. The specific setting or adjustment can be made by professionals in this field according to actual conditions. This is only an example description and is not a specific limitation.

[0049] For example, suppose a power plant has a cylindrical thick-walled header for a power plant boiler with a radius of 1 meter, a wall thickness of 0.1 meter, and a length of 5 meters. During operation, the internal steam temperature is 640°C and the pressure is 16 MPa. Using finite element analysis software, the structural dimensions and material properties (such as elastic modulus, Poisson's ratio, etc.) of the header are input into the model, and the temperature and pressure parameters are set at the same time. The simulation range includes not only the header itself, but also the main steam transmission pipeline connected to it within a radius of 5 meters. After calculation, a stress distribution cloud map is generated. The connecting pipe of the header is displayed as a red high-stress area due to structural mutation, while the straight pipe section of the pipeline has a lower stress and is blue, clearly showing the stress conditions of each part.

[0050] The embodiments of the present application can perform finite element stress numerical simulation of thick-walled components of power station boilers and pipelines within a surrounding target range based on parameters such as the structure, operating temperature and pressure of the components in a high-temperature environment, and generate a stress distribution cloud map, thereby accurately analyzing the stress distribution conditions inside thick-walled components and pipelines under complex working conditions such as high temperature and pressure, and discovering potential problem areas such as stress concentration in advance, which helps to ensure the safety and reliability of power station boiler systems under high-temperature operation and reduce the probability of failures.

[0051] At least one strain collector (such as Figure 1 As shown, strain collectors 301, 302, ..., 30N) are used to generate strain values of at least one high-temperature strain gauge.

[0052] As those skilled in the art will understand, high-temperature strain gauges operate on the principle of the piezoresistive effect of metal or semiconductor materials. Specifically, in a high-temperature environment, when the object being measured deforms due to heat or force, the gauge attached to the surface will also deform accordingly, causing the gauge's resistance to change. By measuring this change in resistance, the strain on the surface can be calculated.

[0053] In some embodiments, in order to facilitate the processing of strain information on the wall surface of thick-walled components of power station boilers, the present application can set up at least one strain collector, use a signal transmission line to connect at least one high-temperature strain gauge and at least one strain collector, and correspondingly collect resistance change information of the high-temperature strain gauge, and then convert the resistance change information into a strain value corresponding to at least one stress change monitoring position on the wall surface of the thick-walled components of the power station boiler.

[0054] Taking the header of a power plant boiler as an example, the present application can select three stress change monitoring positions on the outer wall of the header, and set up a strain collector 301 next to each of the three high-temperature strain gauges 101, 102 and 103, or set up three strain collectors 302, 303 and 304 next to each of the three high-temperature strain gauges 101, 102 and 103. When the boiler is running, the high temperature causes the header to deform slightly, and the resistance of the strain gauge changes accordingly. The strain collector collects these resistance change information in real time, and converts the resistance change into the strain value of the corresponding position based on its own built-in conversion algorithm. For example, at a certain moment, the collector calculates the strain values of the three positions as 0.001, 0.0015 and 0.0008 respectively, thereby monitoring the stress changes on the header wall.

[0055] The embodiment of the present application can use a nickel-based high-temperature alloy high-temperature strain gauge (with a tolerance temperature of above 900 degrees) as a transmission medium, and set at least one strain collector to collect resistance change information of at least one high-temperature strain gauge, and convert it into a strain value corresponding to at least one stress change monitoring position on the wall surface of the thick-walled component of the power station boiler. This can sense the slight deformation of the thick-walled component of the power station boiler due to high temperature, pressure and other factors in real time, and convert it into intuitive strain data through signal transmission and conversion, which helps to timely grasp the real-time stress state of the component, so as to timely discover abnormal conditions such as stress concentration, take measures in advance, and reduce safety risks and energy consumption losses.

[0056] At least one temperature sensor (such as Figure 1 As shown, temperature sensors 201, 202, ..., 20N) are used to collect the actual temperature of high-temperature thick-walled components of power station boilers.

[0057] It's understandable that temperature fluctuations can cause thermal expansion or contraction in the materials of high-temperature, thick-walled components of power plant boilers. Because temperatures can be uneven across thick-walled components, this thermal expansion or contraction varies across locations, generating thermal stress. For example, during boiler startup and shutdown, the temperature difference between the inner and outer walls of thick-walled components is significant. The inner wall experiences rapid temperature fluctuations, causing it to expand or contract at different rates than the outer wall. The resulting thermal stress can potentially damage the component. By acquiring temperature data, we can accurately analyze thermal expansion and assess the impact of thermal stress on components.

[0058] Based on this, in certain embodiments, the present application may include at least one temperature sensor to collect the actual temperature of the high-temperature, thick walls of a power plant boiler. For example, in embodiments of the present application, temperature sensor 201 may be installed on the wall of the steam-water separator; temperature sensor 202 may be installed on the wall of the high-temperature header; and temperature sensors 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 28

[0059] In the embodiment of the present application, when monitoring the stress of high-temperature thick-walled components of a power station boiler, at least one temperature sensor can be set to collect the actual temperature of the high-temperature thick-walled components of the power station boiler. The temperature can be used to understand the thermal stress generated by the thermal expansion and contraction of the high-temperature thick-walled components of the power station boiler, clarify the influence of temperature on the mechanical properties of the material, provide key parameters for the stress calculation of the high-temperature thick-walled components of the power station boiler, and improve the accuracy of the stress calculation.

[0060] Optionally, in one embodiment of the present application, at least one temperature sensor includes: a temperature measuring thermocouple, used to generate a voltage signal of a high-temperature thick-walled component of a power plant boiler; and at least one temperature collector, used to generate the actual temperature of the high-temperature thick-walled component of the power plant boiler based on the voltage signal.

[0061] In some embodiments, the at least one temperature sensor in the present application includes, but is not limited to, a temperature-measuring thermocouple and at least one temperature collector. The temperature-measuring thermocouple can be used to generate a voltage signal from a high-temperature, thick-walled component of a power plant boiler; and the at least one temperature collector can be used to generate the actual temperature of the high-temperature, thick-walled component of the power plant boiler based on the voltage signal.

[0062] Figure 3 This is a schematic diagram of the installation of an armored temperature measuring thermocouple according to an embodiment of the present application. Figure 3 As shown, in the embodiment of the present application, an armored temperature measuring thermocouple can be placed close to the surface of the high-temperature thick-walled component of the power station boiler to be measured at at least one stress change monitoring position on the wall of the high-temperature thick-walled component of the power station boiler, not far from the high-temperature strain gauge installation position, and the pressure block can be welded to the surface of the object to be measured, and the signal transmission wire of the thermocouple can be led out of the insulation layer, and finally protected by a high-temperature heat-melt shrink joint.

[0063] Furthermore, in the embodiment of the present application, a signal transmission line can be used to connect the temperature measuring thermocouple and at least one temperature collector, so that the temperature collector can collect the voltage value of the temperature measuring thermocouple and convert it into the temperature value of the measuring point.

[0064] The embodiment of the present application can accurately measure the temperature of high-temperature components through temperature measuring thermocouples, and convert the temperature signal into a voltage value for easy transmission and processing, which can improve the stability and anti-interference ability of the signal. The temperature collector is then used for secondary conversion to achieve simultaneous acquisition and recording of multiple temperature points, providing critical and accurate data for stress calculation, facilitating better evaluation of the stress state of the components and ensuring safe and stable operation of power station boilers.

[0065] The monitoring component 400 is used to query the material elastic modulus of the high-temperature thick-walled components of the power station boiler using the actual temperature as an index, and calculate the stress value of the high-temperature thick-walled components of the power station boiler based on the material elastic modulus and strain value.

[0066] As those skilled in the art will appreciate, temperature significantly affects the mechanical properties of materials. As temperature increases, the elastic modulus of metal materials generally decreases, along with their yield strength, making them more susceptible to deformation. For example, the elastic modulus of high-temperature, thick-walled components of power plant boilers can vary at different temperatures.

[0067] In certain embodiments, the embodiments of the present application may set up a monitoring component 400 for querying the material elastic modulus of the high-temperature thick-walled components of the power station boiler using the actual temperature as an index, and calculating the stress value of the high-temperature thick-walled components of the power station boiler based on the material elastic modulus and strain value.

[0068] For example, in embodiments of the present application, the actual temperature measured can be used as a basis to search for the corresponding material elastic modulus in a material performance data table or related database. For example, if the actual temperature of a high-temperature, thick-walled component in a power plant boiler is measured to be 650°C, by querying the performance data of the component material (such as P91 steel), it can be determined that its elastic modulus at 650°C is 150 GPa.

[0069] Then, the embodiment of the present application can use the material elastic modulus and strain value to calculate the stress value of the high-temperature thick-walled components of the power station boiler, so as to understand the stress condition of the components and evaluate their safety and reliability.

[0070] The monitoring component 400 of the embodiment of the present application can use the actual temperature as an index to query the material elastic modulus of the high-temperature thick-walled components of the power station boiler, and calculate the stress value of the high-temperature thick-walled components of the power station boiler based on the material elastic modulus and strain value. This can quantify the stress status of the high-temperature thick-walled components of the power station boiler in actual operation, and promptly discover potential stress concentration or overload problems, providing an important basis for the safe operation, maintenance and repair of the boiler, etc., helping to ensure the stable operation of the power station and prevent safety accidents caused by component stress problems.

[0071] Optionally, in one embodiment of the present application, the monitoring component 400 includes: a controller for collecting actual temperature and strain values; a server for receiving the actual temperature and strain values sent by the controller, querying the elastic modulus of the material, and calculating the stress value of the high-temperature thick-walled components of the power station boiler based on the elastic modulus and strain value of the material.

[0072] Based on the relevant descriptions of other embodiments, it can be understood that the strain collector can collect the resistance value of the high-temperature strain gauge and convert it into the strain value of at least one stress monitoring position, and the temperature collector can collect the voltage value of the thermocouple and convert it into the temperature value of at least one stress monitoring position.

[0073] Furthermore, in certain embodiments, the present application may configure a controller to collect signal values collected by the strain collector and the temperature collector, and transmit the collected data to a terminal server via optical fiber.

[0074] Then, the embodiment of the present application can read the monitored strain and temperature values in real time through the server. Based on the actual temperature, the elastic modulus E of the material of the high-temperature thick-walled component of the power station boiler at different temperatures is retrieved from the pre-stored elastic modulus data of the material or a related database, and the stress value of the high-temperature thick-walled component of the power station boiler is calculated using Hooke's law, where the formula can be, but is not limited to, expressed as:

[0075] σ=E×ε

[0076] Where E is the elastic modulus and ε is the strain value.

[0077] The strain and temperature collectors can be connected to the controller via, but are not limited to, signal transmission lines. These collectors are located within 300 meters of the controller, using an RS485 bus in a star configuration. Each controller can support multiple collectors. The controller and server can be connected via, but are not limited to, optical fiber. Single-mode, single-core armored cable should be used in conjunction with an optical transceiver to minimize signal attenuation over long distances.

[0078] By reading the monitored strain and temperature values in real time from the server, the stress values of high-temperature, thick-walled components in power plant boilers can be calculated according to Hooke's law: σ = E × ε. The elastic modulus E can be obtained by querying the material's elastic modulus E at the monitored temperature.

[0079] For example, suppose the controller receives a strain value of 0.003 from a strain gauge and a temperature value of 680°C from a temperature gauge. After optical fiber transmission, this data is received by a terminal server. Based on the temperature of 680°C, the server determines that the elastic modulus E of the component material (e.g., HR3C steel) is 145 GPa. Using Hooke's law, the calculated stress value is σ = E × ε = 145 GPa × 0.003 = 435 MPa.

[0080] It should be noted that the controller and server in the embodiment of the present application can be integrated into the monitoring component 400 or used as separate modules. This embodiment of the present application is for illustrative purposes only and does not impose specific limitations. Furthermore, considering the long distance between the power plant boiler and the power plant control room, the controller in the embodiment of the present application can support the simultaneous expansion of multiple controllers, supporting series or star connections, and adapting to various online monitoring sites.

[0081] In this embodiment, the controller serves as a central hub to aggregate the strain signal values collected by the strain collector and the temperature signal values collected by the temperature collector. These signals are then transmitted to the terminal server via optical fiber, a high-speed, interference-resistant transmission medium. Fiber optic transmission ensures data accuracy and stability during transmission, reducing signal loss and interference.

[0082] The terminal server can read these transmitted strain and temperature values in real time and then query the corresponding material elastic modulus based on the actual temperature acquired in real time. This allows for simultaneous acquisition of strain and temperature, two parameters crucial for stress analysis of high-temperature, thick-walled components in power plant boilers, enabling comprehensive monitoring of component operating conditions. By calculating the stress values of high-temperature, thick-walled components in power plant boilers in real time, the stress state of the components can be monitored and evaluated in real time. This helps to promptly understand the stress conditions of the components and quickly determine whether the components are operating safely, providing a basis for timely maintenance measures or adjustments to operating parameters.

[0083] The following is a detailed description of the embodiment of the present application using a specific embodiment.

[0084] Figure 4 This is a schematic diagram of the installation structure of a stress monitoring device for high-temperature thick-walled components of a power station boiler according to one embodiment of the present application; Figure 5 This is a flow chart of a method for monitoring stress of high-temperature thick-walled components of a power station boiler according to one embodiment of the present application. Figure 4 and Figure 5 As shown:

[0085] Step S501, determining a monitoring position on the surface of a high-temperature thick-walled component of a power station boiler;

[0086] Step S502: polishing the part to be tested to remove the oxide layer and make the surface present metallic luster;

[0087] Step S503, placing the high-temperature strain gauge 2 close to the surface of the monitoring position of the thick-walled component of the boiler;

[0088] Step S504: The high-temperature strain gauge 2 is spot-welded to the surface of the thick-walled boiler component 1. When the component 1 is subjected to force, strain occurs at the measuring point, causing the sensitive grid to deform and change its resistance. This resistance value is transmitted via transmission wire 4 to the strain collector 5, which converts the strain gauge resistance value into the strain value at the measuring point.

[0089] Step S505: A temperature-measuring thermocouple 3 is fixed to the surface of a thick-walled boiler component 1 near the high-temperature strain gauge 2. As the temperature of the thick-walled boiler component 1 changes, its voltage changes. This voltage is transmitted via a transmission line 4 to a temperature collector 6, which converts the thermocouple voltage into a temperature value at the measuring point.

[0090] Step S506: Connect the collectors 5 and 6 to the controller 7 via signal transmission lines. The collectors are distributed within 300 meters around the controller and are connected in a star configuration using an RS485 bus.

[0091] Step S507: The controller 7 is connected to the server 11 via a network cable 8 and an optical fiber 10. The optical fiber is a single-mode single-core armored cable, which is used in conjunction with the optical fiber transceiver 9 to avoid signal attenuation due to long distances.

[0092] Step S508: The server reads the monitored strain and temperature values in real time. The stress value is calculated according to Hooke's law: σ = E × ε. The elastic modulus E can be obtained by querying the value of the material's elastic modulus E at the monitored temperature.

[0093] According to the stress monitoring system for high-temperature, thick-walled components of power plant boilers, an embodiment of the present application proposes a system that uses high-temperature strain gauges and temperature-measuring thermocouples to measure the strain and actual temperature of these components. The stress of these components is then calculated based on the material elastic modulus corresponding to the strain and actual temperature. This system utilizes high-temperature strain gauges as a transmission medium, collects data using strain and temperature collectors, and aggregates the data in a controller for transmission to a server. This system enables real-time online stress monitoring, even in environments exceeding 600°C, through signal transmission and conversion. Furthermore, to address the diverse and dispersed nature of thick-walled components in power plant boilers, the present application employs a modular design. Each collector is a module, allowing for simultaneous stress and temperature monitoring of multiple locations on these components. A module failure requires only the replacement of the collector, resulting in a simple structure and easy maintenance. Furthermore, given the long distances between power plant boilers and the power plant's centralized control room, the controller in the present application supports simultaneous expansion of multiple controllers, supporting both series and star connections, adapting to various online monitoring scenarios. This solves the problem in related technologies that traditional stress monitoring equipment and stress state monitoring methods are not suitable for thick-walled boiler components of high-parameter thermal power units that can even reach temperatures above 600°C during operation. They cannot work in harsh high-temperature environments. Moreover, the thick-walled boiler components are widely distributed, and the distance between high-temperature headers is far. The installation cost is high and the signal is easily interfered with. The applicable scenarios are limited, the subsequent system maintenance is inconvenient, and real-time monitoring is also difficult.

[0094] Next, a stress monitoring method for high-temperature thick-walled components of a power station boiler proposed in accordance with an embodiment of the present application will be described with reference to the accompanying drawings.

[0095] Figure 6 This is a flow chart of a method for monitoring stress of high-temperature thick-walled components of a power station boiler provided in an embodiment of the present application.

[0096] like Figure 6 As shown, the stress monitoring method for high-temperature thick-walled components of a power station boiler includes the following steps:

[0097] In step S601 , the actual temperature of the high-temperature thick-walled components of the power station boiler is collected.

[0098] Step S602 : generating a strain value of at least one high-temperature strain gauge based on the deformation of at least one high-temperature strain gauge.

[0099] Step S603 , using the actual temperature as an index, querying the elastic modulus of the material of the high-temperature thick wall of the power station boiler, and calculating the stress value of the high-temperature thick wall of the power station boiler according to the elastic modulus and strain value of the material.

[0100] It should be noted that the above explanation of the embodiment of the stress monitoring system for high-temperature thick-walled components of power station boilers is also applicable to the stress monitoring method for high-temperature thick-walled components of power station boilers of this embodiment, and will not be repeated here.

[0101] According to the stress monitoring method for high-temperature, thick-walled components of power plant boilers, an embodiment of the present application proposes a method for measuring the strain and actual temperature of these components using high-temperature strain gauges and thermocouples. The stress of these components is then calculated based on the material elastic modulus corresponding to the strain and actual temperature. This method utilizes high-temperature strain gauges as a transmission medium, collects data using strain and temperature collectors, and aggregates the data in a controller for transmission to a server. This method enables real-time online stress monitoring, even in environments exceeding 600°C, through signal transmission and conversion. Furthermore, to address the diverse and dispersed nature of thick-walled components in power plant boilers, the present application employs a modular design. Each collector is a module, allowing for simultaneous stress and temperature monitoring of multiple locations on these components. In the event of a module failure, only the collector needs to be replaced, resulting in a simple structure and easy maintenance. Furthermore, to address the long distance between power plant boilers and the power plant's centralized control room, the controller in the present application supports simultaneous expansion of multiple controllers, supporting both series and star connections, adapting to various online monitoring scenarios. This solves the problem in related technologies that traditional stress monitoring equipment and stress state monitoring methods are not suitable for thick-walled boiler components of high-parameter thermal power units that can even reach temperatures above 600°C during operation. They cannot work in harsh high-temperature environments. Moreover, the thick-walled boiler components are widely distributed, and the distance between high-temperature headers is far. The installation cost is high and the signal is easily interfered with. The applicable scenarios are limited, the subsequent system maintenance is inconvenient, and real-time monitoring is also difficult.

[0102] Figure 7 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present application. The electronic device may include:

[0103] Memory 701 , processor 702 , and computer programs stored in the memory 701 and executable on the processor 702 .

[0104] When the processor 702 executes the program, the stress monitoring method for high-temperature thick-walled components of a power station boiler provided in the above embodiment is implemented.

[0105] Furthermore, the electronic device further includes:

[0106] The communication interface 703 is used for communication between the memory 701 and the processor 702 .

[0107] The memory 701 is used to store computer programs that can be run on the processor 702 .

[0108] The memory 701 may include a high-speed RAM memory, and may also include a non-volatile memory (non-volatile memory), such as at least one disk memory.

[0109] If the memory 701, processor 702, and communication interface 703 are implemented independently, the communication interface 703, memory 701, and processor 702 can be connected to each other via a bus and communicate with each other. The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus. The bus can be divided into an address bus, a data bus, a control bus, etc. For ease of representation, Figure 7 Only one thick line is used in the diagram, but this does not mean that there is only one bus or one type of bus.

[0110] Optionally, in a specific implementation, if the memory 701, the processor 702 and the communication interface 703 are integrated on a chip, the memory 701, the processor 702 and the communication interface 703 can communicate with each other through an internal interface.

[0111] The processor 702 may be a central processing unit (CPU), an application specific integrated circuit (ASIC), or one or more integrated circuits configured to implement the embodiments of the present application.

[0112] An embodiment of the present application further provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the above-mentioned method for monitoring stress of high-temperature thick-walled components of a power station boiler.

[0113] An embodiment of the present application also provides a computer program product, including a computer program, which can run computer instructions. When the computer instructions are executed by a processor, the stress monitoring method for high-temperature thick-walled components of a power plant boiler provided in an embodiment of the present application is implemented.

[0114] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or N embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

[0115] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of technical features indicated. Thus, a feature specified as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of this application, "N" means at least two, for example, two, three, etc., unless otherwise specifically defined.

[0116] Any process or method description in a flowchart or otherwise described herein may be understood to represent a module, fragment or portion of code comprising one or N executable instructions for implementing a custom logical function or process step, and the scope of the preferred embodiments of the present application includes alternative implementations in which functions may be performed in a different order than shown or discussed, including performing functions in a substantially simultaneous manner or in a reverse order depending on the functions involved, which should be understood by those skilled in the art to which the embodiments of the present application pertain.

[0117] The logic and / or steps represented in the flowcharts or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing the logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (e.g., a computer-based system, a system including a processor, or other system that can fetch and execute instructions from an instruction execution system, apparatus, or device). For purposes of this specification, a "computer-readable medium" can be any device that can contain, store, communicate, propagate, or transport a program for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples (a non-exhaustive list) of computer-readable media include the following: an electrical connection with one or N wires (electronic devices), a portable computer disk cartridge (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and programmable read-only memory (EPROM or flash memory), fiber optic devices, and a portable compact disc read-only memory (CDROM). In addition, the computer-readable medium may even be paper or other suitable medium on which the program is printed, since the program can be obtained electronically by optically scanning the paper or other medium and then editing, interpreting or processing it in other suitable ways as necessary, and then storing it in a computer memory.

[0118] It should be understood that various parts of the present application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiment, the N steps or methods can be implemented using software or firmware stored in a memory and executed by a suitable instruction execution system. If implemented using hardware, as in another embodiment, it can be implemented using any one or a combination of the following technologies known in the art: a discrete logic circuit having a logic gate circuit for implementing a logic function on a data signal, an application-specific integrated circuit having a suitable combination of logic gate circuits, a programmable gate array (PGA), a field programmable gate array (FPGA), etc.

[0119] Those skilled in the art will understand that all or part of the steps in the method of the above embodiment can be completed by instructing related hardware through a program, and the program can be stored in a computer-readable storage medium. When the program is executed, it includes one or a combination of the steps of the method embodiment.

[0120] In addition, the functional units in the various embodiments of the present application may be integrated into a processing module, or each unit may exist physically separately, or two or more units may be integrated into a module. The above-mentioned integrated module may be implemented in the form of hardware or in the form of a software functional module. If the integrated module is implemented in the form of a software functional module and sold or used as an independent product, it may also be stored in a computer-readable storage medium.

[0121] The storage medium mentioned above may be a read-only memory, a magnetic disk, or an optical disk, etc. Although the embodiments of the present application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present application. Persons skilled in the art may make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present application.

Claims

1. A stress monitoring system for high-temperature thick-walled components of power station boilers, characterized in that: include: At least one high-temperature strain gauge, the at least one high-temperature strain gauge being disposed on a wall surface of a high-temperature thick-walled component of a power station boiler, the at least one high-temperature strain gauge being deformed when the temperature of the wall surface is greater than a preset temperature; At least one temperature sensor, used to collect the actual temperature of the high-temperature thick wall of the power station boiler; at least one strain collector, configured to generate a strain value of the at least one high-temperature strain gauge; The monitoring component is used to query the material elastic modulus of the high-temperature thick-walled component of the power station boiler using the actual temperature as an index, and calculate the stress value of the high-temperature thick-walled component of the power station boiler based on the material elastic modulus and the strain value.

2. The system according to claim 1, wherein: The at least one temperature sensor comprises: a temperature measuring thermocouple, used to generate a voltage signal for the high-temperature thick-walled components of the power station boiler; At least one temperature collector is used to generate the actual temperature of the high-temperature thick-walled components of the power station boiler according to the voltage signal.

3. The system according to claim 1, wherein: The monitoring components include: A controller, configured to collect the actual temperature and the strain value; The server is configured to receive the actual temperature and the strain value sent by the controller, query the material elastic modulus, and calculate the stress value of the high-temperature thick-walled component of the power station boiler based on the material elastic modulus and the strain value.

4. The system according to claim 1, wherein: Also includes: The installation component is used to determine at least one stress change monitoring position of at least one thick-walled component of a power plant boiler based on a stress distribution cloud map of the thick-walled component of the power plant boiler, so as to correspondingly set the at least one high-temperature strain gauge.

5. The system according to claim 1, wherein: Also includes: A generating component is used to perform finite element stress numerical simulation on the thick-walled component of the power station boiler and the pipelines within a target range around it based on the structural information of the thick-walled component of the power station boiler and the temperature parameters and pressure parameters of the thick-walled component during operation of the power station boiler, so as to generate the stress distribution cloud map.

6. A method for monitoring stress of high-temperature thick-walled components of power station boilers, characterized in that: The stress monitoring system for high-temperature thick-walled components of a power station boiler according to any one of claims 1 to 5 is used, wherein the method comprises the following steps: Collecting the actual temperature of the high-temperature thick wall of the power station boiler; generating a strain value of the at least one high-temperature strain gauge based on the deformation of the at least one high-temperature strain gauge; The actual temperature is used as an index to query the material elastic modulus of the high-temperature thick wall of the power station boiler, and the stress value of the high-temperature thick wall of the power station boiler is calculated according to the material elastic modulus and the strain value.

7. An electronic device, characterized in that: include: A memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the stress monitoring method for high-temperature thick-walled components of a power plant boiler as claimed in claim 6.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that: The program is executed by a processor to implement the stress monitoring method for high-temperature thick-walled components of a power station boiler as claimed in claim 6.

9. A computer program product comprising a computer program, characterized in that When the computer program is executed, it is used to implement the stress monitoring method for high-temperature thick-walled components of a power station boiler as claimed in claim 6.

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